Intercooler: Service and Repair

WM 214319 Removing and installing left and right charge air cooler on 4.8-litre DFI engines

Technical values





Preliminary work

1. Remove front apron. -> 631519 Removing and installing front apron - section on "Removing" . Remove the wheel housing liners at the same time.

Removing charge air cooler





Air guide for V8 Turbo

WARNING

Airbag could inflate when airbag sensor is pulled off.

-> The cable connector for the airbag sensor remains connected. Only the cable from the sheetmetal clip to the air guide is removed.

1. Release airbag sensor cable from sheetmetal clip. Leave cable plug on the airbag sensor. => Cable for airbag sensor





Cable for airbag sensor

2. Pull air guide in front of the charge air cooler off sideways. => Air guide





Air guide

3. Slide air guide behind the charge air cooler off sideways.





Air guide for charge air cooler in wheel housing





4. Disconnect the lower right pressure pipe. To do this, lever off the wire clip using a screwdriver -1- and pull off the pipe. Put wire clip back into installation position immediately. => Lower pressure pipe Release wastegate line and pull it off -A-.





Lower pressure pipe





Pressure pipe with pressure hose at the right (other view)





Ambient air valve at the right, above pressure pipe









Connection for bottom right pressure pipe to charge air cooler





5. Disconnect the lower left pressure pipe -4-. To do this, lever off the wire clip using a screwdriver and pull off the pipe. Put wire clip back into installation position immediately. Release wastegate line and pull it off -1-.





Left pressure pipe





6. Unscrew the two hexagon socket head bolts (M6 x 20) on the pressure pipe -arrows- and pull off the pressure pipe. Other illustrations => Left connection for upper boost pressure pipe => Right connection for upper boost pressure pipe





Mount for pressure pipe





Left connection for upper boost pressure pipe









Right connection for upper boost pressure pipe





7. Pull off air guide to air cleaner housing.





Air guide to charge air cooler

8. Unscrew the three fastening screws on the charge air cooler -arrows- , press the charge air cooler carefully towards the tyres and remove sideways. Sleeves -2- generally fall down.





Fastening screws on charge air cooler





Charge air cooler on bracket






Installing charge air cooler

Information

- Always replace all seals and sealing rings.





Air guide for V8 Turbo

1. Secure the sleeves with a small amount of adhesive or grease before fitting them on the charge air cooler.





Charge air cooler on bracket





2. Move the charge air cooler sideways into installation position and fit the three fastening screws -arrows- by hand.





Fastening screws on charge air cooler

3. Press the air line into the air cleaner housing. This must lock with an audible click. => Air guide





Air guide

4. Slide the pressure pipe with a new sealing ring into the connection piece on the charge air cooler and fit two hexagon socket head bolts on the air pipe -arrow-. Tighten the screws. => Tightening torque: 10 Nm (7.5 ftlb.)





Mount for pressure pipe

5. Tighten the three fastening screws on the charge air cooler. => Tightening torque: 8 Nm (6 ftlb.)
6. Fit the pressure pipes. The wire clip must lock with an audible click -1-.





Lower pressure pipe

7. Slide in the air guides.
8. Place airbag sensor cable into the sheetmetal clip.

Subsequent work

1. Install the front apron. -> 631519 Removing and installing front apron - section on "Installing"